Composite profiles suitable for insulating window units

ABSTRACT

Composite profiles for windows, doors and facades preferably include a profile member  20, 21, 30, 31 ) and a connecting member ( 40, 41 ) extending in a longitudinal direction and respectively having connectable profile and connecting member connecting portions. At least one assembly recess ( 22, 42 ) and at least one corresponding assembly protrusion ( 37, 47 ) are respectively formed on the profile and connecting member connecting portions, each of which comprises form fit elements ( 25, 25   r,    35, 35   r,    45 ) that are connectable by hardening a curable resin. The connecting portions are disposed between sealing devices ( 24, 34, 44, 46, 46   r,    47, 48, 48   r ) that extend along at least one of the profile member and the connecting member ( 40, 41 ), such that the connecting portions are not visible from outside the composite profile when the at least one assembly protrusion is inserted into the at least one assembly recess.

CROSS-REFERENCE

This application claims priority to European Patent Application No. 04001 031.6, filed Jan. 19, 2004, and European Patent Application No. 05000 249.2, filed Jan. 7, 2005, the contents of which are incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates to a composite profile, and in particularto a composite profile for window, door and facade elements.

DESCRIPTION OF THE RELATED ART

Composite profiles for window, door and facade elements of the typerelated hereto comprise two profile members, an outer profile and aninner profile, which are connected to each other by one or a pluralityof insulating elements formed as connection members. 90% of thecomposite profiles used today are made of aluminum, wherein theconnection of the profile members and the insulating members isaccomplished by rolling (bending) as described, for example, in DE 1 101734.

FIG. 7 shows an example of such a known composite profile relating towindow elements. An insulating glass unit 63 is held between seals 61,62 in a window frame formed of composite profiles. A movable compositeprofile comprises a profile member 200 (inner profile) which isconnected via two insulating members 400, 500 formed as connectingmembers to another profile member 300 (outer profile). Another profilemember 60 is attached to the profile member 200, which holds theinsulating glass unit 63 via the seals 61, 62 at the composite profileformed of members 200, 300, 400, 500. The building-side part of thewindow frame is formed of another stationary composite profile made ofprofile members 700, 800 connected to each other via the insulatingmembers 900, 900 formed as connecting members. Seals 65, 640 seal theinterspace between the two composite profiles. In FIG. 7, the connectionof the profile member 300 with the connection member 500 is shown as arolled (bent) connection. The profile members 200, 300, 700, 800 aremade of aluminum. A connecting member connection portion 501 has adovetail-shaped cross section. A profile member connecting portion 301,302 comprises a recess having a dovetail-shaped cross section. One sidewall 301 of the profile member connecting portion is pressed (bent)during rolling in the direction of the other wall 302 after theconnecting member connecting portion 501 has been inserted into therecess, which recess did not yet have the dovetail-shaped cross sectionat the time of the insertion of the portion 501, as described, forexample, in DE 1 101 734.

The composite profiles manufactured by such a known connecting methodhave technical limits, if the aim is to achieve improved thermal valuesand/or to use different or other materials such as wood, plastics andsteel in addition to or alternatively to aluminum for the inner profilemembers and the outer profile members.

The thicknesses of the composite profile and its parts in the directionin which the two profile members face each other (i.e. direction x shownin FIG. 1) are known as the “construction depth”. The rolling processrequires a profile design that only uses about 50% of the constructiondepth of the composite profile for the insulating elements. Thisrequirement limits the thermal values that can be achieved for compositeprofiles of identical construction depth.

The thickness of the walls for the inner profile members and outerprofile members made of aluminum must be larger for a reliable rollingprocess than is necessary to provide adequate static mechanicalstrength. For example, a wall thickness of about 2 mm is needed for areliable rolling process, whereas a wall thickness of only about 1.5 mmis necessary to provide the adequate static mechanical strength.

If the construction depth of the insulating elements is selected to berelatively large in order to provide good thermal values, theconstruction depth of the composite profiles increases significantly. Inthis case, for example, many window types having relatively smalldimensions can not be opened with pivot-and-bottom-hung-mountings.

Furthermore, composite profiles having such large construction depthsalso require larger manufacturing tolerances in the direction of theconstruction depth. The reasons are mainly that (i) the insulatingelements made of plastic have (relatively large) manufacturingtolerances and (ii) dimension changes occur after manufacturing due tofurther crystallization and/or moisture absorption and/or moisturerelease or the like by the plastic material.

The prior art discloses several different techniques for improving theproperties of such composite profiles. For example, EP 0 103 272 A2(family member U.S. Pat. No. 4,525,408) discloses a foaming method. DE 1260 105 (family member GB 1,078,503) discloses a composite profile wherethe members are connected using an adhesive. DE 75 22 009 U discloses acomposite profile, wherein the profile members snap into recesses in aprofile rod and a curable adhesive is used for securing the same. DE-OS2 033 442 A (family member U.S. Pat. No. 4,128,934), DE 27 12 956 A, DE34 23 712 (family member U.S. Pat. No. 4,686,754), and U.S. Pat. No.3,393,487 each disclose composite profiles using a curable resin incomposite profiles. DE 100 33 861 A1 discloses a composite profile,wherein the insulating profile is inserted in the longitudinal directionand is connected using a curable resin afterwards.

EP 0 085 410 A2 discloses another composite profile manufactured byrolling, wherein an auxiliary material such as an adhesive is used foran additional securing of the connection. U.S. 2003/0217818 A1 disclosesa folding device for a room divider or room closure using compositeprofiles. U.S. Pat. No. 4,338,753 discloses an arrangement forconnecting two profile members, wherein a cavity can be filled with ahardenable filler. Also, DE 26 50 944 A1 discloses a composite profilefor window and facade constructions, wherein the connection between theouter profile and the inner profile is made by a connecting bar and theuse of a curable filler, which connection permits movement of theprofiles relative to the connecting bar in the longitudinal directionthereof.

All the known techniques using curable adhesives or resins have thedisadvantage that the shearing strength in the longitudinal directiontends to reduce as the adhesive material ages. Only the above describedrolling approach, in which a significant knurling or roughened or ridgedsurface is provided on the inner side of the aluminum profile member,exhibits sufficient shearing strength for long term use. The otherdescribed composite profiles made by foaming, adhesives, clips or theuse of curing resins may not exhibit sufficient shearing strength in thelongitudinal direction due to deterioration the foaming materials, theadhesives, the resins, etc., over time.

Furthermore, when curable materials are used, problems with surplusmaterial and the visibility of such surplus material frequently occur.

DE 30 33 206 A1 (family member GB 2 083 116 A) discloses a compositeprofile that utilizes a form fit of recesses and protrusions.

SUMMARY OF THE INVENTION

It is an object of the present teachings to provide improved compositeprofiles that overcome one or more problems of the known art.

The present composite profiles advantageously maintain adequate shearingstrength in the longitudinal direction of the composite profile even ifthe adhesion between a cured (hardened) connecting material and profilemembers and/or the connecting member fails due to aging. Preferably, aform fit is provided between form fit elements, such as a first andsecond holding element, which form fit, is maintained by the cured(hardened) connecting material. This form fit is present in both thetransverse and longitudinal directions, i.e., not only in thelongitudinal direction as in the known art. Because rolling (bending) isno longer necessary to form the composite profiles, a variety ofmaterials, such as aluminum, wood, plastics, etc., can be used in anycombination for the profile members.

Furthermore, constructive constraints caused by the known rollingprocess are alleviated, such that the amount or percentage (length) ofthe profile members in the construction depth of the composite profilecan be reduced and the arrangement of the profile member connectingportions and the connecting member connecting portions is possiblewithout the geometrical constraints caused by the known rolling process.

Further advantages and features of the present teachings will beapparent from the following detailed description of the embodiments withreference to the figures and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a cross sectional view perpendicular to the longitudinaldirection of a window frame comprising two composite profiles accordingto the present teachings.

FIG. 2 shows, in view a), the embodiment of FIG. 1 with two framesenclosing connection elements, and in views b) and c), enlarged views oftwo frames in sequential steps of mounting the connection elements usingan adhesive and the final mounted state thereof.

FIG. 3 schematically shows in views a) to c) the mounting of the rightside portions of the composite profile of FIG. 1.

FIG. 4 shows a first modification of the embodiment of FIG. 1 in viewscorresponding to the views of FIG. 2.

FIG. 5 shows a second modification of the embodiment of FIG. 1 in viewscorresponding to the views of FIG. 2.

FIG. 6 shows a third modification of the embodiment of FIG. 1, whereinthe views in a) and b) correspond to the views of FIG. 2 b) and c), andview c) shows a metal sheet with knurling which has not yet been bent.

FIG. 7 shows a window frame made of composite profiles according to theprior art.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a window frame with composite profiles according to onerepresentative embodiment of the present teachings. The longitudinaldirection (i.e., the z direction) of the composite profiles extendsperpendicularly to the paper plane (x and y directions) of FIG. 1. Thewindow frame may comprise two composite profiles. A first compositeprofile 10 may comprise a first profile member 20 (e.g., an innerprofile that is arranged at an inner side of a building frame (notshown)) and a second profile member 30 (e.g., an outer profile that ismovable with respect to the stationary building frame). The firstprofile member 20 is connected to the second profile member 30 by afirst connecting member 40 formed as an insulating element. The firstprofile member 20 is connected to the second profile member 30 via thefirst connecting member 40 by a cured (hardened) connecting material 50,such as a curable resin that hardens after curing or the like, in amanner that is described in more detail further below. In this manner,the members 20, 30, 40 form the first composite profile 10. Anotherprofile member 60 is mounted on the connecting profile 10 such that aninsulating glass unit 63 is held between seals 61, 62. Such aconstructional unit forms the movable part of an insulating windowframe.

The building-side or fixedly disposed part (when mounted on thestationary building frame) of the window frame is formed by a secondcomposite profile 11 that may comprise a third profile member 21 (innerprofile) and a fourth profile member 31 (outer profile) connected by asecond connecting member 41 formed as an insulating element. Theinterspace between the two composite profiles 10, 11 is sealed by theseals 64, 65 when the window is closed. The members 21, 31 and 41 arealso fixedly connected using a curable connecting material 50, as willbe described further below.

The direction x shown in FIG. 1, i.e. the direction in which the firstprofile member 20 faces the second profile member 30, is referred to asthe transverse direction hereinafter. The construction depth of thecomposite profiles 10, 11 and its constituting parts/members is theconstruction depth in the transverse direction. The directionperpendicular to the transverse direction and perpendicular to thelongitudinal direction is indicated hereinafter as the horizontaldirection y (from left to right in FIG. 1). The same definition of thelongitudinal direction, the transverse direction, and the horizontaldirection will be utilized herein for all figures and the description ofall embodiments and modifications.

In FIG. 2, the embodiment of FIG. 1 is shown in view a). View b) showsan enlarged view of a first frame marked in view a), in which sequentialmounting steps and the final mounted state are shown. View c) shows anenlarged view of a second frame marked in view a) in an analogousmanner.

The first profile member 20 comprises a first profile member connectingportion which is shown in the second frame of FIG. 2 a). This firstprofile member connecting portion extends over at least a part of thelength of the first profile member 20 in its longitudinal direction,more preferably over the complete length of the first profile member 20.Referring to FIG. 2 c), the first profile member connecting portioncomprises an assembly recess 22 extending in the longitudinal zdirection. The assembly recess 22 is formed by a recess bottom 22 b andtwo walls 23, 24 protruding from the recess bottom 22 b essentially inthe transverse direction. The recess 22 has a generally U-shaped orsimilar cross section which is open on one side such the depth directionof the assembly recess 22 extends essentially in the same direction asthe transverse direction, i.e., essentially parallel thereto. In theembodiment shown in FIGS. 1 and 2, one of the two walls is freestanding,namely wall 24. The volume of assembly recess 22 corresponds to thevolume defined by the two walls 23, 24, the recess bottom 22 b and ahorizontal line perpendicular to the terminal end of the freestandingwall 24.

First form fit elements are preferably formed as teeth-like protrusions(holding elements) 25 on one of the two walls 23, 24. In the embodimentshown in FIG. 2, three rows of protrusions 25 are arranged on the wall23 in the longitudinal direction. The protrusions 25 are spaced inlongitudinal direction, such that continuous intervening spaces orrecesses are present between rows of protrusions 25 in the longitudinaldirection and intermittent intervening spaces or recesses are presentbetween individual protrusions 25 in the longitudinal direction.

A second profile member connecting portion of the first profile member20, which is not shown in FIG. 2 in detail, is formed in a similarmanner. However both walls defining the assembly recess are preferablyfreestanding. Whether and how many walls of the assembly recess arefreestanding will be discussed below with reference to a representativeholding device.

The first connecting member 40 preferably comprises a first connectingmember connecting portion having an assembly protrusion 47. The assemblyprotrusion 47 is preferably formed as a protrusion because it isinserted into the assembly recess 22 when the profile members 20, 30 andthe connecting members 40 are connected. In other words, the assemblyprotrusion 47 preferably should protrude from the connecting member 40to at least an extent that allows insertion of the same as describedbelow. On one side of the assembly protrusion 47, form fit elements areformed as protrusions (second holding elements) 45. In the embodimentshown in FIG. 2, three rows of protrusions 45 are again arranged in thelongitudinal direction with recesses (interspaces) therebetween.

In the mounted state (i.e., the right most frame of view c)), theassembly protrusion 47 is inserted into the assembly recess 22. Thus,the first and second holding elements (protrusions 25, 45 face eachother and do not overlap in the longitudinal direction. As shown in themiddle frame of view c), the assembly recess 22, or more precisely theinterspace between the wall 23 having the first holding elements 25 andthe assembly protrusion 47 having the second holding elements 45, isfilled with a curable (hardenable) connecting material 50 in an uncured(liquid) state before the assembly protrusion 47 is inserted into theassembly recess 22, as will be further discussed below. Thereafter, theconnecting material 50 is cured or hardened.

Because the protrusions 25, 45 are arranged in rows with interspaces inthe longitudinal direction, a form fit is provided between the first andsecond holding elements (protrusions) 25, 45 and the cured (hardened)connecting material 50. Accordingly, adequate shearing strength in thelongitudinal direction is ensured, irregardless of whether adhesionbetween the connecting material 50 and the first profile member 20and/or the connecting member 40 is lost or diminished due todeterioration caused by aging.

Adequate shearing strengths in the transversal direction and thehorizontal direction are also ensured by this form fit between theprotrusions 25, 45 and the connecting material 50, again irregardless ofwhether the adhesion between the connecting material 50 and the first orsecond profile members 20, 30 and/or the connecting member 40 is lost ordiminished due to deterioration caused by aging.

In the representative embodiment shown in FIGS. 1 and 2, the firstconnecting member connecting portion shown in view c) also comprises awall 48 extending in parallel to the assembly protrusion 47. Theassembly protrusion 47 and the additional wall 48 define an interspace(recess) 49. The width (in the horizontal y direction) of the interspace49 is selected such that it is less than or equal to the width (in thehorizontal y direction) of the freestanding wall 24. When the assemblyprotrusion 47 is inserted into the assembly recess 22, the freestandingwall 24 is inserted into the interspace 49, preferably by elasticexpansion of the width of the interspace 49 between the assemblyprotrusion 47 and the additional wall 48. In this case, after theassembly protrusion 47 has been inserted into the assembly recess 22 tothe desired extent, a holding force is generated due to friction betweenthe freestanding wall 24, the assembly protrusion 47 and the additionalwall 48. This holding force will hold the position of the first profilemember 20 relative to the connecting member 40 independent of the curingof the connecting material 50, as long as no force larger than thisholding force is applied thereto. Accordingly, in this embodiment, thefreestanding wall 24, the assembly protrusion 47 and the additional wall48 form a holding device. If such a holding device is utilized, at leastone freestanding wall preferably should be provided.

However, as can be seen from another representative embodiment shown inFIG. 5, such a holding device may be eliminated. In this case, until theconnecting material is cured, the relative positioning of the membersoptionally may be maintained by other (e.g., external) means.

In the representative embodiment shown in FIGS. 1 and 2, thefreestanding wall 24 is preferably arranged on the side of the assemblyrecess 22 that is directed towards the outside of the profile members,i.e. the potentially visible side, if at least two connecting portionsare present at the corresponding profile/connecting members. By means ofthis arrangement, it is ensured that any excess or surplus resin(connecting material), which could spill out of the recess 22 during orafter the assembly protrusion 47 is inserted into the assembly recess22, is not visible from outside the composite profile. The samearrangement preferably may be utilized for all other pairs of connectingportions of the corresponding profile/connecting members so as toimprove the visual appearance of the final product.

The second profile member 30 preferably comprises a second profilemember connecting portion as shown in greater detail in view b) of FIG.2. This second profile member connecting portion preferably comprises anassembly protrusion 37 on which form fit elements (e.g., protrusions)may be formed as second holding elements 35 in the same way as theassembly protrusion 47. The first connecting member 40 preferablycomprises a second connecting member connecting portion, which is alsoshown in detail in view b). This second connecting member connectingportion comprises an assembly recess 42 defined by a recess bottom 42 band two walls 43, 44 and extends in the longitudinal direction in asimilar way as was described above with respect to the assembly recess22. On a first wall 44, form fit elements (e.g., protrusions) 45 areprovided as first holding elements in a similar way as the protrusions25. The form fit between the second profile member 30 is secured bycuring (hardening) the connection material 50 in the same manner as wasdiscussed above with respect to the form fit between the first profilemember 20 and the connection member 40.

As shown in greater detail in FIG. 2 b), a second holding device isformed by the freestanding wall 34 which extends in parallel to theassembly protrusion 37, and an additional freestanding wall 46, whichextends in parallel to the first wall 44 disposed outside of theassembly recess 42. The walls 44, 46 define an interspace (recess) 49having a width slightly less than or equal to the thickness of thefreestanding wall 34. In this case, a holding force between the walls44, 46 is generated when the assembly protrusion 37 is inserted into theassembly recess 42 in an analogous manner as the above-described holdingdevice.

Accordingly, the holding devices of the first representative embodimentshown in FIGS. 1 and 2 preferably include one freestanding wall (whichalso may be called a “clamped element”) disposed on one member and twowalls extending in parallel (which also may be called a “clampingelements”) disposed on a second member. The two parallel walls arepreferably separated by a distance that is slightly less than or equalto the thickness of the freestanding wall such that after the insertionof the freestanding wall into the interspace (i.e., the recess betweenthe parallel walls), a holding force is generated due to the friction.Naturally, these walls should preferably be arranged (positioned) suchthat the freestanding wall is inserted into the interspace while theassembly protrusion is being inserted into the assembly recess and suchthat the freestanding wall is inserted into the interspace when theassembly protrusion is being inserted into the assembly recess. Thefreestanding wall and the two parallel walls preferably, but notnecessarily, form one of the two walls defining the assembly recessand/or the assembly protrusion.

In the embodiment shown in FIGS. 1 and 2, the first connecting member 40comprises four connecting member connecting portions. Two connectingmember connecting portions each are respectively assigned for connectionto the first profile member 20 and the second profile member 30. The twoprofile members 20, 30 each comprise two corresponding profile memberconnecting portions such that a total of four pairs of connectingportions are present. With respect to the embodiment shown in FIGS. 1and 2, it is noted that the connecting member connection portions arenot required to be positioned in the same plane in the horizontallydirection (see, for example, the connecting portions between the firstprofile member 20 and the connecting portion 40).

All assembly recesses 22, 42 are identically oriented, i.e., in the samedirection, such that the depth direction is substantially parallel tothe transverse direction (e.g., with a deviation from the transversethat <±30°, preferably <±20°, more preferably <±10°, even morepreferably <±5°, and most preferably <±2°) and the recesses openings areall oriented in the same direction.

Further, the freestanding walls (clamped elements) 24, 46 of eachholding device, i.e., one for each pair of the connection portions ofthe profile and connecting members 20, 30, 40, are preferably arrangedsuch that they are positioned on the outer side of the correspondingconnection portions. As a result, spilled resin (connecting material 50)will not be visible from the outside of the composite profile after thefreestanding wall 24, 46 has been inserted into the interspace betweenthe two parallel walls (clamping elements) 44, 46, 47, 49 of the holdingdevice. In this case, the holding device also serves as a connectingmaterial “covering” device or a connecting material “sealing” device.These additional or alternative functions of covering and sealing,respectively, the connecting material are not limited by the holdingfunction. If the holding force is not sufficient to hold the componentsuntil the connecting material cured or if external holding devices areused, the sealing function is still maintained.

In this representative embodiment, two types of connecting portions areprovided. The first type includes the assembly recess 22 like the firstprofile member connecting portion and the second connecting memberconnecting portion. The second type includes the assembly protrusions37, 47 like the first connecting member connecting portion and thesecond profile member connecting portion.

Preferably, the connection portions of the same type present in onecomposite profile all have the same orientation in the transversedirection.

Furthermore, it is noted that the share (proportion) of the firstconnecting member 40, i.e., the insulating element, along theconstruction depth is significantly greater than in the prior art. Thisis possible, because no rolling (bending) process is required, as in theprior art, whereby the connecting portions do not have to be designatedto receive a large force without breaking.

The above description applies similarly to the second composite profile11 shown in FIG. 1.

According to the present teachings, the above-noted problems of theprior art with respect to dimensional accuracy in the transversedirection can be solved in a simple manner, because the assemblyprotrusions 37, 47 are inserted into the assembly recesses 22 until thedesired dimension is obtained. After that, the members 20, 30, 40 aremaintained with this desired dimension in the transverse directioneither by means of an external holding device or by means of the abovedescribed integrated holding devices until the connection material 50 iscured. Therefore, dimensional problems caused by varying manufacturingtolerances of the members 20, 30, 40 can be overcome. Such manufacturingtolerances are always present in composite materials, for example, dueto (i) manufacturing using different manufacturing machines, (ii)different materials, (iii) subsequent crystallization of theplastic/resin material, (iv) water absorption by the plastic/resinmaterial, (v) water release thereby, etc. Accordingly, a plurality ofcomposite profiles 10, 11 can be manufactured with the same dimensionsin the transverse direction (=construction depth) independent of themanufacturing tolerances of their constituent members.

The problems present in the above-described known composite profilesmanufactured using a rolling process also can be overcome without thedisadvantages of the above-described known alternative solutions. Forexample, significantly more than 50% of the construction depth of thecomposite profile can be occupied by the insulating element 40, the wallthicknesses can be reduced, freely selectable materials can be combinedfor the inner profile members 20 and the outer profile members 30 andrelatively high thermal values can be obtained without increasing theconstruction depth. Moreover, the problems caused by varying ordifferent tolerances in the transversal direction and the visibility ofspilled resin or the like also can be overcome. Furthermore, reliabilityproblems can be overcome with respect to reduced shearing strength inthe longitudinal direction caused by deterioration of the adhesive dueto aging.

Additionally, 5-head-solutions (i.e., composite profiles having 5 pairsof connecting portions) as shown in the composite profile 11 of FIGS. 1and 2, which have not been obtained using known rolling processes, arepossible without problems in accordance with the present teachings.

The assembly recess 22 serves as a reservoir for the non-curedconnecting material. Preferably, the volume of the connecting material50 filled into the assembly recess 22 does not exceed the volume of theassembly recess 22. More preferably, the volume of the connectingmaterial 50 filled into the assembly recess 22 is less than the volumeobtained by subtracting the volume of the assembly protrusion 37, 47from the volume of the assembly recess 22 (see e.g., FIG. 2 b),right-most view). However, it is also preferable that this volume isless than the volume remaining after inserting the assembly protrusion37, 47 between the freestanding wall 24, 34 and the opposite wall 23, 43of the assembly recess (see e.g., FIG. 2 c), right-most view).

A further advantage of the representative embodiment shown in FIGS. 1and 2 results in that the assembly of the members 20, 30, 40 in thetransverse direction can be performed such that no protrusions, members,dovetails, connecting elements or the like are required to be insertedin the longitudinal direction of the composite profiles in order toovercome other tolerance problems.

The materials for the profile members 20, 21, 30, 31 can be freelyselected from materials such as wood, steel, plastics, aluminum, othermetals, etc. For example, weather-resistant materials can be used forthe outer profiles on the other hand. On the other hand, the materialsfor the inner profiles 20, 21 can be selected by putting more emphasison the insulating properties thereof such as synthetic materialsincluding e.g., polyamide or PET having good heat-insulatingcharacteristics.

The curable connecting material can be selected from a variety ofcurable resins, such as but not limited to poly-urethanes,poly-ethylenes and/or epoxies.

In preferred embodiments, the resin is suitable for powder coating. Forexample, the resin preferably may be resistant to degradation attemperatures of 200 to 220° C. for 20 to 30 minutes and/or in a cleaningbath if the composite profile will be subjected to an anodizing process.

Preferably, at least the visible surfaces of the connecting members 40,41 are conductive (e.g., have an electrical resistance less than 10⁻⁹Ω). This property serves to ensure that the materials can beelectrostatically coated. This conductivity can be achieved, e.g., byapplying a conductive primer to the surface of the insulating element40, 41 and/or by introducing a conductive material into the insulatingelement 40, 41, if necessary.

In FIG. 3, a representative method for manufacturing the first compositeprofile is shown schematically. First, the first profile member 20, thesecond profile member 30 and the first connecting member 40 areprepared. Then, the (identically oriented) assembly recesses of thefirst profile member 20 and the first connecting member 40 are filledwith a predetermined volume of the curable connecting material 50, forexample via filling nozzles 102 in a corresponding filling machine 101(see FIG. 3 a)). Subsequently, the (identically oriented) assemblyprotrusions of the first connecting member 40 and the second profilemember 30 are inserted into their corresponding assembly recesses in thetransverse direction (see FIG. 3 b)). In the embodiment of the compositeprofile shown in FIG. 3, the above-described holding devices areprovided such that, after inserting the assembly protrusions, therespective members and the desired dimension (=construction depth) inthe transversal direction can be obtained without using external holdingdevices. Moreover, if any connecting material spills over, it can not beseen from the outside of the composite profile.

FIG. 4 shows a first modification of the embodiment shown in FIGS. 1 and2. Specifically, the holding devices of FIG. 4 are formed differently.In the representative embodiment shown in FIG. 4, the interspaces(recesses) 49 of the holding devices are formed such that they inwardlytaper towards the opening in the cross section perpendicular to thelongitudinal direction. Knurlings or grids 46 r, 48 r are formed on theinner sides of the walls 44, 46 and 47, 48, respectively, facing theinterspace. Corresponding knurlings or grids (not shown) may be formedon the freestanding walls 46, 48 that will be inserted into therespective interspaces 49. When the assembly protrusions 37, 47 areinserted into the interspaces 49, the interspaces 49 are widened againstthe resilient elastic force of the defining walls 44, 49, 47, 48 and theknurlings or grids 46 r, 48 r engage each other in the end position. Asa result, the holding force is not only generated by the resilientelastic force of the walls 44, 49, 47, 48 and the corresponding frictionbut also by the engaging knurlings or grids 46 r, 48 r. Therefore, theholding force can be significantly increased and the holding can be mademore reliable, if desired.

FIG. 5 shows a second modification of the embodiment shown in FIGS. 1and 2, in which no holding devices are provided. In the embodiment shownin FIG. 5, it is also possible to omit the freestanding wall 34 (seeFIG. 5 b)).

FIG. 6 shows a third modification in which the inner surfaces of thefirst and second holding elements include knurlings 25 r, 45 r. Such aknurling, e.g., may consist essentially of protrusions and/or recessesand results, in case of a suitable selection of the curable connectionmaterial, the same effects and advantages as the larger protrusions. Theprofile members 20 and 30 shown in FIG. 6 can be obtained by bending apre-knurled metal sheet, as shown in FIG. 6 c).

Alternatively, the first and/or second holding elements, i.e., theprotrusions and/or recesses, can also be obtained by providing net-likestructures, engravements, dimples, especially rough surface structures,such as a roughened wood surface, etc. The present teachings are notparticularly limited in this regard.

In all embodiments described and shown in the figures, the orientationof the depth direction of the assembly recesses, the protrusiondirection of the assembly protrusions and the corresponding insertiondirection of the assembly protrusions into the respective assemblyrecesses preferably each correspond to the transverse direction, whichallows equalization (compensation) of different manufacturingtolerances. The equalization of the tolerances is also possible fororientation of the depth direction of the assembly recess and theprotruding direction of the assembly protrusion and the correspondingdirection of the insertion of <±90° in relation to the transversedirection. However, even in case of corresponding orientations and aninsertion perpendicular to the transversal direction, all advantagesexcept the equalization of the tolerances are obtained.

The first, second and third materials of the claims can be freelyselected and they are not limited to a single material. For example, thethird material can comprise a plurality of materials, e.g., theconnecting member can be formed partly of polyamide and partly ofpoly-urethane-foam, and/or the first profile member (first material) canbe partly a synthetic material like plastic and partly wood and/or thesecond profile member (second material) can be partly metal and partly asynthetic material like plastic.

Each of the above-described features and teachings may be utilizedseparately or in conjunction with other features and teachings toprovide improved insulating window units and methods for designing andusing the same. Representative examples of the present invention, whichexamples utilize many of these additional features and teachings bothseparately and in combination, were described in further detail withreference to the attached drawings. This detailed description is merelyintended to teach a person of skill in the art further details forpracticing preferred aspects of the present teachings and is notintended to limit the scope of the invention. Therefore, combinations offeatures and steps disclosed in the detailed description may not benecessary to practice the invention in the broadest sense, and areinstead taught merely to particularly describe representative examplesof the present teachings.

Moreover, the various features of the representative examples and thedependent claims may be combined in ways that are not specifically andexplicitly enumerated in order to provide additional useful embodimentsof the present teachings. In addition, it is expressly noted that allfeatures disclosed in the description and/or the claims are intended tobe disclosed separately and independently from each other for thepurpose of original disclosure, as well as for the purpose ofrestricting the claimed subject matter independent of the compositionsof the features in the embodiments and/or the claims. It is alsoexpressly noted that all value ranges or indications of groups ofentities disclose every possible intermediate value or intermediateentity for the purpose of original disclosure, as well as for thepurpose of restricting the claimed subject matter.

1. A composite profile suitable for a window, door or facade element,comprising: at least one profile member extending in a longitudinaldirection, the profile member comprising at least one profile memberconnecting portion, at least one connecting member extending in thelongitudinal direction, the connecting member comprising at least onecorresponding connecting member connecting portion arranged andconstructed to be connected to the at least one profile memberconnecting portion such that at least one pair of correspondingconnecting portions is present, wherein one of the profile memberconnecting portion or the connecting member connecting portion comprisesat least one assembly recess extending in the longitudinal direction andthe other of the profile member connecting portion or the connectingmember connecting portion comprises at least one assembly protrusionarranged and constructed to be inserted into the assembly recess in adirection perpendicular to the longitudinal direction, wherein the atleast one assembly recess comprises a plurality of first form fitelements and the assembly protrusion comprises a plurality of secondform fit elements such that the first and second form fit elements areconnectable in a form fit by a curable connecting material disposedwithin the assembly recess, and at least two sealing devices extendingalong the longitudinal direction of at least one of the profile memberand the connecting member, wherein the corresponding connecting portionsare disposed between the at least two sealing devices such that theconnecting portions are not visible from outside the composite profilewhen the at least one assembly protrusion is inserted into the at leastone assembly recess.
 2. A composite profile according to claim 1,wherein: the at least one profile member comprises at least two profilemember connecting portions, the at least one connecting member comprisesat least two corresponding connecting member connecting portionsarranged and constructed to be respectively connected to the at leasttwo profile member connecting portions such that at least two pairs ofcorresponding connecting portions are present, at least one of the atleast two profile member connecting portions or the connecting memberconnecting portions each comprise at least one assembly recess (22, 42)extending in the longitudinal direction, the other or the at least twoprofile member connecting portions or the connecting member connectingportions each comprises at least one corresponding assembly protrusionarranged and constructed to be inserted into the at least one assemblyrecess in a direction perpendicular to the longitudinal direction, eachassembly recess comprises a plurality of the first form fit elements,each assembly protrusion comprises a plurality of the second form fitelements such that the first and second form fit elements areconnectable in a form fit by the curable connecting material disposed inthe at least one assembly recess, and the corresponding connectingportions are arranged between the at least two sealing devices such thatthe connecting portions are not visible from outside the compositeprofile when the assembly protrusions are inserted into the assemblyrecesses.
 3. A composite profile according to claim 1, wherein: the atleast one profile member comprises a first profile member made of afirst material and a second profile member made of a second material,the at least one connecting member is made of a third material and isarranged and constructed to be connected to the first profile member andthe second profile member such that the composite profile extends in afirst direction over a first length, at least one of the first profilemember and the second profile member comprises the at least one profilemember connecting portion and the at least one connecting membercomprises the at least one corresponding connecting member connectingportion, and the at least one assembly recess and the at least oneassembly protrusion extend in the longitudinal direction over at least apart of the first length.
 4. A composite profile according to claim 1,wherein: the at least one assembly recess comprises a plurality of firstholding elements serving as the first form fit elements, which aredisposed along the longitudinal direction and protrude or are recessedperpendicular to the longitudinal direction, and the at least oneassembly protrusion comprises a plurality of second holding elementsserving as the second form fit elements, which are disposed along thelongitudinal direction and protrude or are recessed perpendicular to thelongitudinal direction.
 5. A composite profile according to claim 1,wherein: the at least two sealing devices are holding devices arrangedand constructed to hold the position of the at least one profile memberrelative to the at least one connecting member after the at least oneassembly protrusion has been inserted into the at least one assemblyrecess, independent of the insertion depth and independent of the curingof the connection material.
 6. A composite profile according to claim 1,wherein: the at least one assembly recess is defined on one side by afirst wall that protrudes from one of the corresponding profile memberor the corresponding connecting member.
 7. A composite profile accordingto claim 6, further comprising: a second wall adjacent and parallel tothe at least one assembly protrusion defined by the first wall such thatthe first wall is positioned between the at least one assemblyprotrusion and the second wall after the at least one assemblyprotrusion has been inserted into the at least one assembly recess,wherein the first wall, the second wall and the at least one assemblyprotrusion define one of the at least two sealing devices and serves asa first holding device arranged and constructed to hold, by a holdingforce, the first wall positioned between the second wall and the atleast one assembly protrusion.
 8. A composite profile according to claim7, further comprising: a third wall adjacent and parallel to the firstwall and a fourth wall adjacent and parallel to the assembly protrusion,wherein the fourth wall is arranged and constructed to be positionedbetween the first wall and the third wall after the at least oneassembly protrusion has been inserted into the assembly recesses,wherein the first wall, the third wall and the fourth wall define one ofthe at least two sealing devices and serves as a second holding devicearranged and constructed to hold, by a holding force, the fourth wallpositioned between the first wall and the third wall after the at leastone assembly protrusion has been inserted into the at least one assemblyrecesses.
 9. A composite profile according to claim 1, wherein the depthdirections of the at least one assembly recess and the protrudingdirections of the at least one assembly protrusion are substantiallyparallel.
 10. A composite profile according to claim 4, wherein thefirst holding elements and the second holding elements extendperpendicularly to the longitudinal direction such that the firstholding elements and the second holding elements do not overlap whenviewed along in the longitudinal direction.
 11. A composite profileaccording to claim 2, wherein: the at least one profile member comprisesa first profile member made of a first material and a second profilemember made of a second material, the at least one connecting member ismade of a third material and is arranged and constructed to be connectedto the first profile member and the second profile member such that thecomposite profile extends in a first direction over a first length, atleast one of the first profile member and the second profile membercomprises the at least one profile member connecting portion and the atleast one connecting member comprises the at least one correspondingconnecting member connecting portion, each assembly recess and eachassembly protrusion extend in the longitudinal direction over at least apart of the first length each assembly recess comprises a plurality offirst holding elements serving as the first form fit elements, which aredisposed along the longitudinal direction and protrude or are recessedperpendicular to the longitudinal direction, each assembly protrusioncomprises a plurality of second holding elements serving as the secondform fit elements, which are disposed along the longitudinal directionand protrude or are recessed perpendicular to the longitudinal directionthe at least two sealing devices are holding devices arranged andconstructed to hold the position of the at least one profile memberrelative to the at least one connecting member after the assemblyprotrusions have been inserted into the respective assembly recesses,independent of the insertion depth and independent of the curing of theconnection material.
 12. A composite profile according to claim 11,wherein: each assembly recess is defined on one side by a first wallthat protrudes from one of the corresponding profile member or thecorresponding connecting member.
 13. A composite profile according toclaim 12, further comprising: a second wall adjacent and parallel toeach assembly protrusion defined by the first wall such that the firstwall is positioned between the assembly protrusions and the second wallafter each assembly protrusion has been inserted into its correspondingassembly recess, a third wall adjacent and parallel to the first wall,and a fourth wall adjacent and parallel to the assembly protrusion,wherein the fourth wall is arranged and constructed to be positionedbetween the first wall and the third wall after each assembly protrusionhas been inserted into its corresponding assembly recesses, wherein thefirst wall, the second wall and the assembly protrusion define one ofthe at least two sealing devices and serves as a first holding devicearranged and constructed to hold, by a holding force, the first wallpositioned between the second wall and the at least one assemblyprotrusion, and wherein the first wall, the third wall and the fourthwall define a second of the at least two sealing devices and serves as asecond holding device arranged and constructed to hold, by a holdingforce, the fourth wall positioned between the first wall and the thirdwall after each assembly protrusion has been inserted into itscorresponding assembly recess.
 14. A composite profile according toclaim 13, wherein the depth directions of all the assembly recesses andthe protruding directions of all the assembly protrusions aresubstantially parallel.
 15. A composite profile according to claim 14,wherein the first holding elements and the second holding elementsextend perpendicularly to the longitudinal direction such that the firstholding elements and the second holding elements do not overlap whenviewed along in the longitudinal direction.